Influence of inclination angle, shape and size of the flow channels on the AlSi10Mg complex products fabricated by selective laser melting

The design and manufacture of complex products with flow channels produced by the Selective Laser Melting (SLM) have attracted much attention due to its influence on the practicability of products. In this research, the inclination angle, shape and size of channel were compared on the complex products produced by SLM. Besides, the surface quality and forming difficulty of AlSi10Mg were investigated. As shown by the results, the overhang length played a key role in collapse, which was determined by inclination angle. In addition, the limited inclination angle was attributed to the position relationship between the inclination plane and the moving direction of the scraper. Meanwhile, the ridge-shaped flow channels had an advantage on surface quality and dimensional accuracy over the circular channel. No matter whether the section of the flow channels is circular or ridge-shaped, the size of the flow channels should be designed equal or >2 mm. The complex product with flow channels had been successfully produced by SLM without remaining powder or defects, which could withstand 2 MPa for 5 min. Furthermore, the CT test is suitable to investigate the forming quality of the flow channels, especially whether there is remaining powder inside the flow channels. Especially for the complex product with flow channels, it provides an integrated detection method based on X ray test and CT test for remaining powder, internal surface quality or internal defects. In addition, the design idea and criteria of three-dimensional flow channels based on the SLM technology provide a basis for the design of other products with flow channels.